November 9, 2023

The Sirio, a perfect solution, from Meccanotecnica

The Meccanotecnica Digital Book Trimming machine has won praise for its speed of trimming variable size books with high quality and multiple functionalities. These include double cutting for oversize trims, and processing books with eight-page gatefold covers in one pass.
Now to complete the system the groundbreaking Sirio digital perfect binder has been launched. It is a completely new development of a three clamp binder, with the capability to run at 1350 copies per hour, and to process single book production.

The digital functionality and control is impressive, but equally important is the industrial build quality of the machine and the rugged design of key elements including 250mm diameter milling head and twin cover scoring shafts. The highest book quality is guaranteed, with a maximum of six scores per cover.

The Sirio has a patented clamp drive system to enable each clamp to be independent, but sharing the drive of one robust chain, ensuring component longevity, and eliminating timing settings. Available now for softcover production, the range will further expand during next year with the introduction of automatic book feeding, book endpapering, PUR spine gluing, and a lining station for hard-cover book production.

The Sirio adhesive binder reflects a shift in emphasis for Meccanotecnica. Building on their long-time expertise in sewn book machine design and production they are utilising their extensive R&D facility to become a leading full solution provider in book finishing.

November 16, 2022

Meccanotecnica’s recent Open House

Meccanotecnica’s recent Open House was a great success. The four day Book Your Future event saw 275 visitors, from 31 countries. They were able to network, exchange ideas, projects, and visions, on the book industry’s future. Every day, live demonstrations showed visitors how to produce books more efficiently and cost-effectively. A total of 60,000 books were produced during the event.

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In focus was the new generation of the Full Cycle® technology with Uniplex-asterPRO. eliminating the empty lock stitch machine cycle. This improved system, combined with the process integration brought by the gathering and sewing line, showed how to increase efficiency in producing sewn books.

The event also provided the unprecedented opportunity to showcase all the three Meccanotecnica Universe versions, the market-leading equipment for producing digitally printed sewn books.
Technical partners Rotolito Spa, LegoDigit Srl, Hunkeler AG, FAI (Fondo Ambiente Italiano), and Ultimate Technographics Inc, were involved and helped to make the event a success.

July 12, 2022

KOLBUS UK take on Schmedt book production range

KOLBUS UK are pleased to announce that they are now the “go-to” people for bookbinding machines manufactured by Schmedt GmbH & Co KG.

Based in Hamburg, Germany, Schmedt manufacture a range of high-quality machines for all areas of hard cover book production and finishing. They focus on small to medium run solutions, so their machines dovetail perfectly with the KOLBUS range of larger capacity equipment. KOLBUS UK customers benefit from full technical support with technicians based in the UK, and a spare parts stock at Houghton Regis.

The Schmedt range includes machines for book block manufacture, embossing, casing in, edge printing and attachment of headbands and bookmarks, with KOLBUS UK focusing on the medium to high production machines in the Schmedt range.

Greg Bird, KOLBUS UK managing director said: “We’re proud to be able to formalise this new agency agreement. For some time we have referred KOLBUS UK customers to Schmedt if they were looking for smaller equipment. We’ve done this with confidence because we were impressed with the high quality of their German made machines, very much reflecting the standards we know from KOLBUS GmbH. Now that we are Schmedt’s machinery agent we can offer a full technical and spare parts service to our KOLBUS UK customers.”

November 9, 2021

Bell & Bain invest in KOLBUS casemaking

After many years of attempting to persuade Bell & Bain to install KOLBUS casemaking equipment the decision to invest was ultimately a quick one. Existing equipment was causing production issues and increasing downtime. Despite the difficulties caused by the pandemic, negotiations took place remotely with an order being placed by Bell & Bain without a machine demonstration or factory visit. So, their first purchase of a KOLBUS DA casemaker was done on trust.

Installation was carried out by KOLBUS UK within one week of delivery with training of the operators in the following weeks.

The DA 270 is the perfect model in the KOLBUS DA range for book printers. It not only delivers a high running speed of 3,900 cases per hour, but also provides a fully automated make ready to minimise changeover times. Its simple operation demystifies high speed casemaking and provides high level output for both long and short run lengths. In addition, the ability to connect the DA 270 to the KOLBUS 360 service portal enables 24/7 service support to be on hand.

Stephen Docherty, Bell & Bain chairman, said “Installing this first KOLBUS DA270 casemaker has been nothing short of game-changing. We want to make books for as many customers as we can, and to the highest quality that we can. This KOLBUS machine takes us to another level in achieving this. It dovetails into our existing factory, is fast and easy to operate, and gives us a platform for further expansion.

Just as important as the quality of the machine is the level of support that we’ve received from the whole KOLBUS team. From placing the order through installation to operator training they have been with us to help and advise.”Bell & Bain invest in KOLBUS casemaking

Installation was carried out by KOLBUS UK within one week of delivery with training of the operators in the following weeks.

June 26, 2021

Westbury Packaging upgrade their short to medium run boxmaking capacity

Perfectly stacked boxes at Westbury Packaging

Cardboard packaging manufacturers Westbury Packaging serve clients throughout England and Wales from their Melksham, Wiltshire, base. They offer a full range of cardboard packaging solutions including distribution boxes, point of sale, and branded packaging for e-commerce. The increasing demand for bespoke packaging in short to medium run lengths was stretching their existing short-run equipment to its limits and meant that they were taking capacity away from their range of volume machinery. Their search for a more efficient and flexible replacement led them to KOLBUS Autobox.

Managing director, Ben Tupman, and head of operations, Alan Jane, of Westbury Packaging, visited the KOLBUS Autobox UK manufacturing site in Houghton Regis. They were able to see the machines in action running production jobs from 0201’s to large tray/lids, and 0401 Maltese cross designs. Alan Jane said: “Having looked at a range of options in the market we opted for KOLBUS Autobox mainly because it is a UK engineered product. When visiting the factory, it was clear that they stock a huge range of spare parts available for quick turn-around. They have their own components site to manufacture any bespoke parts on demand. They also have a team of UK based engineers. None of the other competitors offered this service.” Last month Westbury Packaging installed a KOLBUS Autobox AB300, Flexo print FP300 and Multicut MC300 with powered separation and air locks. They were supplied with 200 mm and 700 mm slotting knives for a more refined machine. The new installation has enabled them to set up bespoke sized jobs within one to two minutes. Adding print taking an extra five to ten minutes to set up, with the flexibility to print up to 1000 mm x 1000 mm on designated panels or every panel. One of their designs was a 4000 mm Chop x 2200 mm Deckle 0201, with print and hand holes. A high value product that would have required at least two or three processes as well as costly tooling. The KOLBUS Autobox produced this in a single pass, and at speed. At the other end of the scale, they produced a small, 700 mm x 400 mm 0409, with obscure internal dimensions. Westbury Packaging’s Alan Jane said: “Purchasing the KOLBUS Autobox has enabled us to move several processes in to one, saving hours of set time each day and hundreds of pounds worth of tooling. The KOLBUS Autobox Boxmaker makes high value, notoriously difficult jobs, much easier and faster to run. Since installation, we have run a huge range of products through the machine, it hit the ground running. We are getting even more out of it than we thought we would. The print unit in particular has been extremely useful for us, we feel as though it has always been there!” Arran Sethi, KOLBUS UK, said: “We are fortunate to be a part of a demanding industry that keeps our UK manufacturing business busy. As the UK Sales Manager I have to thank companies like Westbury Packaging for putting their support in us. For me, it was clear that our machinery would help to modernise their short run department. It has also helped them to maintain their position of being a Carbon Neutral company.

March 17, 2021

In-house control of challenging packaging for Glasstops

Glasstops UK are a Norwich based manufacturing and processing company producing almost anything in flat glass. From table-top protectors through mirrors coloured worktops, delivered nationwide.
Up until recently orders ready for despatch were packaged in wooden crates, individually tailored to the product being shipped. Whilst this was safe, it was a costly and time-consuming way to manage their outgoing deliveries. Glasstops managing director, Daniel Dunwoody- Kneafsey, heard from industry colleagues that cardboard could be a viable alternative packaging material. A google search of “bespoke boxmaking” took them to Youtube videos of an AutoBox machine in action. Impressed they visited the manufacturing site in Houghton Regis for a demonstration (in the pre-Christmas period before lockdown).

For the demonstration, KOLBUS AutoBox produced a number of bespoke boxes that represented Glasstops actual product sizes. Taking them back to Norwich a glass table top was then shipped from Norwich to South Wales, and then back again. The products arrived back in Norwich having sustained no damage at all. Dunwoody-Kneafsey said: “at one point we decided to literally throw the package around on our concrete floor to test its durability. The product was absolutely fine”.

Suitably impressed Glasstops UK ordered a KOLBUS AutoBox BOXER BX200 and Table feeder TF200. KOLBUS UK were able to deliver and install the machines last month. Installation was completed on day one with the first boxes being made by day two.
Dunwoody-Kneafsey commented: “Moving from timber to corrugated transforms our business. Even though our volumes aren’t huge the turnaround time and cost saved, compared to timber, offers us a rapid ROI.

Arran Sethi, KOLBUS UK sales manager, said: “Some of Glasstop products are 3,500 mm long by 1,500 mm wide and 50 mm tall, very awkward sizes. Very often they would need just one bespoke box at a time. Our KOLBUS AutoBox BOXER machine can set jobs remotely. It does not need an operator at the machine. The table feeder will auto feed the sheets and out pops the box ready to be used. It is so simple and efficient.

The KOLBUS AutoBox BOXER is an ideal solution for companies like Glassttops UK that need exact sized boxes as and when they are required. They are a typical end-user customer where a lot of their manufacturing process is automated and on demand. The BOXER follows this mould. It is set up within 60 seconds to produce a bespoke size or style or grade of box. There is minimal manual interaction”.

February 25, 2021

Cumberland Packaging invest in KOLBUS Autobox MultiNova

Cumberland Installation AutoBox MultiNova

To satisfy increasing demand for short to medium run cartons in a wide variety of styles Cumberland Packaging have invested in a KOLBUS Autobox MultiNova corrugated box making machine. With its fast make-ready the MultiNova will free up capacity on their larger volume automatic folder gluers. The KOLBUS Autobox MultiNova MN400 was delivered to their Southend sheet plant in early January. Installation was completed in a day with a further two days for training. Operators were running the machine at 1,200 boxes per hour by close of play on day one.

The KOLBUS AutoBox MultiNova is a multi-point gluer, ideal for short-medium and large run lengths of straightline and crashlock corrugated boxes. Set-up times are fast: five minutes for straightline and 15 to 20 minutes for crashlock; saving up to 45 minutes per set-up compared to four-to-six-point gluers. It runs at average speeds of 1,500 to 2,000 boxes per hour with up to 4,000 per hour achievable on smaller boxes.
The MultiNova represents an ideal way to take three-point work in-house at an affordable price. It is a compact machine, the compression section is under the machine as opposed to after, saving considerably on floor space compared to more automatic machines. Although the MultiNova can be run by a single operator up to three can be deployed depending on production requirements. One operator always collects the 90% closed boxes, finishing them and controlling the quality of finish using the “squaring system” to avoid fishtailing. This is an essential requirement to limit waste, especially when producing short to medium run lengths.

Mark Bennett, Cumberland Packaging production manager, said:” We invested in the MultiNova to enable us to bring the smaller and awkward panel work in-house and to speed up the manual operation. We wanted to free up capacity on our large volume automatic folder gluers. We can set up the MultiNova for one to 2,000 straightline boxes and in that time will have increased our capacity on a high-volume machine significantly. The KOLBUS AutoBox installation and training went extremely well, quickly reaching quality and running speeds that we had planned for”.

Arran Kohli Sethi, KOLBUS AutoBox sales manager, said: “It has been great working with Mark and the Cumberland Packaging team on this project. They have made some significant investments over the last 24 months to achieve aspirational goals for year-on-year growth. This machine will help them to develop a particular area within their varied business.
The MultiNova is simple to operate and very adaptable. It has its own niche in corrugated box finishing where quick set times and reasonable run speeds are required. It is neither a semi-automatic machine nor a fully automatic machine but offers the benefits of both, cost effectively”.

December 2, 2020

KOLBUS short run casemaking solution for Prime Group

on Tolley, with newly installed KOLBUS DA 270

With the current pandemic causing disruption in the supply chain, and Brexit just around the corner, the personalised and on-demand book trade is looking closer to home for manufacturing solutions. To capitalise on this South Normanton based Prime looked to produce high quality cased books, on demand and in runs starting at one.

With 18 digital presses and high speed inkjet printers within the group Prime could fulfil the requirements of publishers for the printing of medium and long run backlist titles, and runs of one, but needed to streamline their hard cased book production line to cope with producing the wide variety of book sizes and quantities. To do this Prime turned to KOLBUS UK for a solution and have now installed a KOLBUS DA 270 casemaker along with a KOLBUS EMP 513 casing in line at their new facility in South Normanton, conveniently located just off junction 28 of the M1 motorway.

The KOLBUS DA 270 casemaker delivers fully automatic production of cases and digitally printed book covers with varying spine widths at rates of up to 65 cycles/minute. It is a versatile machine for a wide range of applications.
The non-stop case feeder is designed to be easily operated by one person. The centre strip cross-cut unit is capable of automatically changing cutting widths from cycle to cycle. This allows the machine to produce, for example, hardcover photobooks where centre strip width is likely to vary from product to product. Width adjustment is completely automatic during running production with no change of material.
Jon Tolley, director of Prime, said: “the challenge was to be able to supply absolutely top-quality cased books in the on-demand marketplace. These KOLBUS machines are enabling us to do just that. We researched the market and nothing else touched the throughput and capabilities of these machines. The KOLBUS DA 270 has full digital capacity, perfect for the high number of size changes and run lengths we have through every shift. The efficient board cutter also minimises our inventory for board. With a reduction in man hours we are producing absolutely beautiful quality products in a fraction of the overall time we were taking”.

KOLBUS UK managing director Greg Bird said: “It is particularly pleasing to see how the recent digital developments of the KOLBUS DA 270 has made the KOLBUS casemaking solution the perfect fit in the short run digital market, allowing the known benefits of KOLBUS quality and productivity to be available to an ever growing digital book sector. Prime were keen to explore the full range of digital options available on the KOLBUS DA range and it was clear that this was the right solution, both for the present and for the developing future production needs of Prime.

We were able to provide comprehensive training of new operators for the DA casemaking machine and recently purchased KOLBUS EMP casing in machine which together provide an exceedingly high specification digital cased book production facility at Prime’s new premises”